oil FORD CAPRI 1974 Workshop Manual
Page 6 of 205
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About this manual
Its aim The OIUll 01111'$ 111,11111;,1 IS 10 hel l} you lid the l}cS I v~llIe from yOl" vchicl.:!. 11 Cilll do SO III seve.;)1 ways II eml hOllp you dccllh~ wh,,! work Illust be done (eyell should YOIi chou$u 10 III!! 1 duno by OJ IF"Il\lu). pro v ide ulfo'Ill.1100tl 011 touiU1C Il"HIlICIl;UICU ;)lId SCfVIC"\~. "lid give 11 lo Uic .. 1 f01USC u l :'C I'OII nlld d"'!J"OSIS whe n ,,1Ildom f<lult s oceul Howcvc •. "'S h OIIC\llhm YOli wdl usc the ,,\lUlu,,1 hy 1.,eldonu the wo.k yuurself. On S""ph,H lol>s II mily (:11(:11 he (,ulcke . 1II,In booklllU the til' Illio .1 !J,"<lye .. ",t! HOII'!I 1h,,,e tWice. 10 ICiIVC ;md collCCI U. PClh;ll)S mOSI lIuporlan!. ;1 101 of mOlley Cim be s:lVcd hv ;wo,(/mg the COS1S" O;lf"IJc Il1l1S1 ch ... uc 10 cuver liS r .. bOUf ,IIlU ovcrhCi1(ts. The In<1nu<11 h ilS d,,,wIIlUs nnd (ICSc"pllons 10 show Ihe lunC1Ion 01 Ihe V;:lriOliS componcnts ~() Ih"t thell 1,IyoIII r.,lll be (lI1d eI5100( 1 Theil Iho wsks mc d esc"hed "1Il 1 phO loUI"phed 111 iI ste p · by· step se(l"encc so Ih<11 even " novice C,ll1 do Ihe wOlk
Its arr.1ngemellt T he 1I1,1I1Uili is dll/lded 11110 twelve Ch,lt)lels. cilch cOI/Ollng illogic .. 1 suu·dil/ision 01 Ihe 1/(lI .. dc The Ch"lllels ,lIe encll dll/illed 11110
SCCtlons. numuClcd wllh slll\lle IlyUles. eg 5. and the Sec tion s "ltO p",ag'ilphs (01 sub·seCllons). wllh Occll11,,1 numbels following 011 110111 Ihe Sociion Ih ey nlc III . <)1.1 5 1. 5 2. 5 3 elc . h IS froely illusltnted. espccl"lIy III those paris where Ihele is il delalled sequcnce of opel allons 10 be carricd ou1. Thelo ilre Iwo fo rm s
of IILUS";I\IOII 1r!IUfeS ;111f1 ph(lt<lO,"phs The 11~lur~ .IIt: ,,"mhered In sequencc wllh clecl"';11 nlllllllcl~. ;rcr.ord1ll! 1 In Iii"" I'OSllllll1 III Ihe
Ch;1pler c!J Fill G II IS Ihe 10lllih !I"l\VIII!J/IIIII~Ir<1llnn III Ch"plc! G
1'1>010g'"ph 5 C,lllY Ihe s,"lle ",""llO' (ell hOI rrld ,v l{h lollly 01 III 'el"led Uroups) '"S Ihc Sec lion 0' $1I1I,s(lCIIO" 10 which Ihey rel"I". There IS (III illph(lllcllCillllidex ;lllhe h.lr.k of Ihe I11"nuill;1S well , 's il COl1lell iS Irs t ill Ihe !r OIll E.1Ch Chilplel IS ilho 1}leceded hy liS own rn(lrl/rdu(ll coments IrSI Rclerence~ 10 the ·Ie ft· or 'tI~h" 01 Ihe III;h ,r;le arc III Ihe sensc 01 n person In Ihe (Irll/er's scm filCIIIO lorw,lrds. Unless olhclwlsc stilted. nulS ilrld holls ;lIe rcrllow,d hv '<11111119 nntl·clockwlse. "lid lighlclled hy l",n"'\1 r;i {){ :kwls,) Vehicle 1lI11Iwl" clu.ers conllnually 1Il., ke chilll!Jcs to spcr;lloco1llUIIS ~lId reCO IIIIllCl1d lltloIiS. (l1I(t Ihese. wiron notified. ,,'e IIlCO rPOI(lI"d 11110 our rll""Uills ill Ihc eilrlrest oppOllunlly Whils t el/ery care is la ken to ensure Ihnl the in lorrnillion in this mant"'! is correct. no liilbility can be ilecelHed by Ihe auth ors o r publishers fo r loss. dam~ge o r injury cilused by any errors in. or omissions from. the inlorma tion gil/en.
Proje ct veh icle The vehic le u se d In the prep,lfillion aflhis mo1nu~l . and ilppcnrinu in Illilny of Ihe phO IOIJr"phiC sequences. \V,lS a Ford Cilj)ri 2.8 InJeCllon.
Introduction to the Capri V6
Tile C(lpri It mode ls wcrc lirs t Introduccd '" Ihe UK in February 1974 uSing il Wide rilflUC of engrncs prcl/iously used on olher Ford I/chicles. T he mod(lls cOl/ered III Ihls ","llu,,1 usclhe V6 3.0 hlrc Esse~ alld V6 2 8 litre Cologne engines The restyled Sories III models were Introduced in Marc h 1978 W,lh a Ironl spoll!;:r (Ind 10Ul headlilnlps. and lollowrng Ihls Ih e 2.8InJCCIIOfl vers.on was launchcd on July 1981. Seplernl»e r 1984 saw Ihe Inlroductloll 0 1 the high pcrlolJ.l1(1nce 28 Injection Special which
leatwed a IrnHwd shp d,f!elcI1tlal. lockilble spoked alloy whecls (Ind il higher lel/el 01 Inlellor III'" In 1987 Ihe lilS I CilprrS w ere mildo .. Ihe limiled edllrOI) 280 The Cilr 1$ conl/cnilonai III IlIcch"nlCilllayoul. dlil/e from Ihe ellgille being trnnstllilled 10 Ihe re"r ilxle IhrOllgh iI II or 5·speed nl;111Uill gearbox or alternatll/ely Oil S(llies II JIIodels. a 3 ~Jlecd (Iulomat>c IransmlSSlon
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Page 8 of 205
Jacking and towing
Jilckillg poillls To chan!IC ,I WhUt:1 111 ,11 ,-,"W'!ICIICY. usc the t:]ck slIpplled wilh the ve'lIe!!.!. Ensurf! 1hal the Hhldwh,:cl nuIS;OH! ,ciC;lSCd Imlole Ii, cklll\j up thO ca. and make SlUe Ih;u the .lOIn of the 1,1Ck IS luU.,. cnua\Jcd wI,h the body bracket and thatlhe hase allhe Jilek IS st;lIldlt '!J on a 111111 surface. The Jilek supplied w!lh lhe vehIcle IS 1101 $",,;,l)le lor lISC when laislflg the ve!.iclc lor U\;J",l()II;IIlCC or 'Cp,1If up,:r;J110ns. For this walk, use a trol ley. hyd'ilui,c Of screw-Iype tad IOCille(1 und!:. thO f,OIll crOSSlllcmbcr. bodylrame s,(ic-mcmbcls 01 ,ea, il~le cnsing, .1$ ,UuSlr<llcd AlwilyS supplcl11ullt the I.lck wilh axlc-Sl.1llds or blocks t)Cfo,e cfilwhnu bC'H!.11h the em
Usin g the lilling jnck
Fronl IOwin9 pain I S (ll • • owed )
Towing poillls II you/ vehIcle ,s bCIIl9 IOWl;d, m,lke SUfe lhal the lOw rope IS auached to Iho 110111 cmssmembcr or, where Ilued. the towlog eye auachcd 10 Iho 11001 ClOssmember II Ihe vehicle IS equipped wilh atilOma llC Iraosrlllsslon, the d.slanCe lowed rnuSI nOI exceed 15 miles (24 km). 00' Ihe speed 30 mph (48 km/h), olhe.wise sefious damage 10 Ihe Ir<rnsmiSSIOII rnny .estili. If Ihese IlinilS arc likely 10 be exceeded disconneC I and remove Ihe propeller shnh.
I f you me lowrnn another vehicle, minch a lOW rope 10 Ihe lowc. shock absorber mounting brilCkct at thc axlc lube or, If fined, Ihc rCilf
10Wlflg eye.
, 'I I -J ' ,;
~)
'J
: .. ': .... 111"'"' ..... _-.___ •• _...:. __ ... ,
Jacking l)oinl S
Rear towing I)oio \s (arrowe d )
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Page 9 of 205
Buying spare parts and
vehicle identification numbers
Bllyillg spare parts Sp;'1rc p"rlS ;lre ilwul.1!Jlc from momy sources. Jo. exam ple FOHI uar"gcs. oliler gil':lgCS ,-mtl ncccssu.y shOIIS. im(i mOlor ';.elms 0", a<iv IC(! rcga.d'l1l) SPillC pill 1 sources IS ;.s follows Ollici,lllV ,11lI'Olll/cd FQI(I y,l','Y~S Th,s IS the be:.! SOUfeu of IlilllS which me j>(!CUh,1' 10 you. C,l' ;'1n($ ilfe olil(),w lsc 110( \jClll:;,;)liy aViul,li)le (cg complC1C cylll,!ie. he;]!!s. Ill'Crololl !Jcn,tJOK components. hadU"s. mlelio •• ,,'" CIC ). IllS alS(lllm only pl,rcc a[ wluch you should buy PiUIS If you. C;'l, IS SI,II lIIuhn W<1"<1l1ly nun Ford 1:0"'11011""15 111,''1' tnvahdalC lhe W.l"'lIlIy To h e Sllte uf ulllau""H Ih. ) C(ln"U P;lIlS " wIll nlwilys he neccss:lty to \)'VC the Sl0rw",lIl YOIII CilO'S "dllcl.) ,dcn.,tica\lon l1umh.1" ;mll .1 IIOSS.lJlc , 10 toke the 'old' pail ;.lol1g 10 '
I lOSII.ve idenlil leallol1, Bumcml)C. ,h;'1 .,,;,ny p;rrlS illt) ;'Yirrl;.hle on a InelOry exclHlnge schelllC illly PililS .elurne(1 should nlw,1ys he clennl II obviously makes oood snnse 10 go S\""Uhl \0 Ihn SIICel.1hsts on you. CM lor this Iype 01 PMI as Ihey n.e besl equipped Il) supply you O/hef yM,'yes Im.1 m:cesSOlr shops These a.e ollen ye'Y goot! plnces 10 buy Illate".lls al1<l eomponems needed 10. the IllnUlienallCe 0 1 you. en. (eu 011 IlltCIS, SI)ilrk plugs, lJulbs, drove belts, 0115 iHlt!
\J.caS(lS, louch-up p;um, lilie. pilstC etc) 1 hcy also 51'11 !Jene.al
ileccssoflcs, uSlIillly l \.lye conyenlent opcnUlU hours, Ch.11Ue I, prices and can often be lound nOI la. hom home MOlor 1,7C(0IS ~ Good lacto.s will stock illl Ihe mOle Illlp,,, comllOnen lS which wea. oul .elilhycly qUI ckly ((..'9 Clutch COIllI,cm. PISIOI1S. villyes. e~hilusl systems. IJr;lku cyhnlie<s/p'lK:s hoses I ... , shoes alld pads elc). MotOr faClOls Will often ploYlrie I\/:V. .ccondlhoned components on a pall eXCh,lrlue hilSIS IllIs tilll Sd consule'ilhle amO\UlI 01 money!
Vehicle itlenlificc1l;OIl numbers Altholl!lh milny uuhviduill pa.ls. 1md ill some cases sub-ass/:mlo III a lIU1nlJm 01 dlflerent models II IS dallge,ou$ 10 a ssUllle tll;1 \JCCilU5e they look the 5,lIn e, Ihey a.e the same. Dillelences n.e nlwilys e.1sy 10 detect excepl l.Iy serial numtJCrs Make su.e the.e th;otille ilPI),op"ale identify number for the mode! or suh-asseml.lt known .1n(l Quoled when a spare PMt is obtained. '"c v(!/m;fc irlCl!lrfrc.lfioll "IMe is mounted on the rIght-hand tr Will\! ilpron on SCries II models or on the righl·hand Side of Ihe f, Cfossmemher on Selles III models.
Vehiclo ident ifictltion philO location (Series III)
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General repair procedures
Whenever scrvie,,,U. repair or overhaul work ,$ c;nric<i out Oil the eM or its components, ,t IS nl:c",ss;uy In nUsc."o the lollowtll\j procedures (Iud ulslruct'{JIlS. Ttus w,lI assis t III ca"ylll(j out Ihe opcrJlion eff Iciently ,1nd to " p,()lcsslollal slanlia,d of workmimstup
Joinl mating ftlces ,7l1d gaskets Where 1'1 gasket IS lIsed tmlwl:CIl the ",,,,ill\1 [<lees 01 two components, OnSlIr(l Ih;)t It IS renowed un Icassclllhly. Bnd 111 it dry unless O(IHJlwise Slaled III the rcp;Hr plOGcdw() Milke SlUe that the nmling (<lees nrc cle;m [lnd dry with "II II,lees of uld \Ja~;kCl rClllov ct1 When cleaning 11 tOnH j<lCC. use il 1001 which,s not likely to scorc Or dalllil(lC the l<lcu, [l1ll1 reillove <lny 1>I'''s or nIcks wnh an oilstone or hno Ide.
Make SUfi) lh,,[ tnppcd holes nrc ciedncd WIth il pI pc clcilncr, and kcep thcm flcc 01 101l1llng compound If tillS IS helll\) used unless
speCIfIcally Instructed otherWIse Ensure that "II ollfrtes. (:hannels 0 1 pIpes ,lie Clt'ill ilnd blow thlough Ihelll. p,eleriluly llsing compressed ill(
ai/ seal s
Wheneve, nn od sCill is removed flom its wOlkll1\1 10Ciliion, eIther mdlvidu"lly or "s p"rt of iln assemhly, It should be lencwcd The very finc sc"lIng IIp of the sei'll IS e"slly dama\Jcd and WIll not seal If the surface it COI11<1(:15 IS not completely c lean and free frOlll
SCHl\ches, nicks 0' grooves. If the o'iginal scaling surfi'lce of the COlnponern cannOI he restorCd, Ihe component shoul d he renewed, PrOlect lhe lips of the scal from any surlace which mi'lY damage them in the course of fmlng. Usc wpe or a conical sleeve where POSSIble, LUb ricate the senl lips WIth 011 befole fruing and, on dual lipped se"ls, fill the space be twcen the hps With grease. Unless otherwise stated. all seills must be hlled with then sealing hps toward the lubricilrH to he seillcd Use iI\ubuli'l' <111ft 01 block 01 wood 01 the npploprime sIze to II1sta ll
) I he scal ilnd, lithe sCi,1 housing IS ~houldeleu. drive the seill down to the shoulue,. If the scal hOUSIng is unshouldcred, the seal Should be fItted with its lace flush W ith the hou$lIlg top face,
Screw IhrCiU/s and lasleoings Always cnsurc that a blind t"pped hole is completely free from orl. U
reilSe,
wilte, or other flUId hcfore instatllng the hott a' stud. Fililu'e 10 do tillS could C,luse thc housm\) to c"lck due to the hydrilulic <1ction of the bolt or slud ilS It IS sc,ewed '" When tluhtenlllU ,1 cilswllilled nut to ilCCCpt iI spht pin, tIghten the nut to the speCIfIed torque, whele ilpphcilh le, and then lIghten furthe, to the next split pin hole Ncver slilckenlhe nulla "lrgn a spirt pin hole unless ~t<l1ed III the ,epil" plocedure When checkIng or retlghwnlllg il nut or holt 10 ,1 specified 10'Que setUIlg. slilcken the nul o r bolt iJy a qua'ter of a turn. "nd then retighten to the speclflcd setting
Locknuts, /ockt.1bs and wasliers Any fo1SlC(1Ong which wdl rotate agaillst a cO!llponen! or hO\ lsing in the course of lI\)hlemng shmrld illways hilve a wilsher between it ilnd the relevil"t component 0' hOllSlllg Sprm<J or spirt w.1she,s should illwilyS be rencwcd when they ilre uscd to lock a c'"trcnl con'ponem such n5.1 blg·end beillmg letalll"'g nut 0' bolt. Locktilbs which il'e fohied over to re t;1in a nut or bolt should illwilyS b e renewed. Self -lockIng nU1S c<ln be reused in non-crit'cal il reJS, p roviding reSlstJ l1Ce Ciln be felt when t he lockmg portion passes ove, the bolt or stud th,eild. Spht pillS must always be ,eplaced with new ones 01 the correct size lor the hole.
Special tools Some repal( procedures III this manuill enWil the lise of special 100ls such ilS il p,ess, two or t hree-legged pulle,s, spring compressors etc Wherever pOSSIble, suitJble ,eildrly ilvailable altcrnatlves 10 the manul(lctu,ers special tools a,e descrrbed, and are shown in u sc. III
SOllle Inswnces, where no a lterniltlve IS poss ible. II hilS been necessary 10 resort to the use of a manufilclurer"S tool and thIS has been done for reilsons of safety as well as Ihe eHlcien! completion of the repair
operation. Unless you are highly Skilled ilnd hilve a thorough unde,standlng of the procedure desc(lbed, neve, " tWlllpl to bypass the use of any specl,,1 tool when the procedure descrIbed specllies ils use, Not only IS I here a ve,y great risk of pe,sonal Injury, but expensive dillllage could be causJd 10 Ihe components involved
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Page 11 of 205
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Tools and working facilities
Intra d!le I iOIl
A ~CICC1101l of good 100ls IS il fUlldillll! :lllill (C(j""Clllcnt Jor ''''yOIlD cOlllcmplilllO\llhc l1lilUHenilllCli <lnd rep;'" of il mOlor velHcle Fur 110" OWIll" who does not P()S~(;SS ,"'y. IIio" purCh,lS!) wolf prove il conslUCJilblc expense, offsCI!OIlU some of the S<lVlll!)S 111,1(1" hy doing· ii-yourself . Howev!:'. provl(led Ihal the tools purd"ISf! d ,II.., of good qUilllly. tiluy will lasl 101 Ill,l"y yca,s <lnd PIOV!) illl ex(,elllcly worthwhile IIlvCSllllcnL
To help the ;;!Vernge owner 10 decide which tools ;IIe needed to c;ury OUi Ihe various lilsks detailed in thiS 1l101J1UOI. we hi!vC compiled Ihree lists of lools under the followinu hColUinus: M;"i'(CJlM1CI) and millO' rcpair, Repair allii on',h,wl. <llld Speci,ll The newcomer 10 practical mechanics should S!<Jrl off wilh Ihe MaiIlICf!ilf!cC "lid millor fuwm 1001 kll ,mu contOile hilllsell 10 Ihe simpler Jobs alounu Ihc vehIcle . Then. ilS his confidence and expenence Urow. he C<ln undelwke "'Ole dlfflcull l<lsks, bUYlny exlrJ I~Ols <lS. i11ld when, Ihey ale needed In II"s WiIV, " MilIIIICII,If>Ct' ;lIId millOf fI.'p;m 1001 k'l Cil" be I)u oil -uII'III 0 " R ul'.m ;lIId oVf.'lh;wllool kil over a cons,der<l!!lc pc, ,ou of I,,,'e wnhoul ""V 111,'101 cil~h oUII,lys The cXIICllencnu do- n · vourselJt:r woll h"ve <I luol kIt Huotl cnough for 1110S1 rep"" <lnd ovelh"ul proccdurcs ilIHI Will ,Idd IUols f'onl Ihe Spcc,,1f c.rlegory whell he lee ls Ihe npense '5 IUSllhcd iJy Ihe ,1111Ulll1l of US!} 10 which Ihese lools Will be PUI.
It IS obvluusly nOI pOSsll)le 10 cover Ihe subJeCI of lools fully hr;l(! For Ihose who WIsh 10 le.lm llIorc aboullools .;n(l Ihei, usc Ihclc Is;r IJOok enlilled How 10 Clioose ,111d Use Cilt lools "v,,,I<lhle from Ihe puhlishers ollhis 1I1,'l1uill.
Main/enallce (lnd fIIinor repair /001 kit The 100is \lIven III Ihls IrSI should be consideled ilS a IIw"mW11 requllelllcnl II rOUlllle 111i1lnleni
ce. S«IVIC"'U ,1I1d ""11 or repa " Oper"llons illC 10 he unde!l<lken. We recoillmend Ihe PUlchilse 01 conrbillilllOn spilnners (ring one end, open·.ended Ihe olher). ;rllhOll\lh 1l10re expensivc lhnn open-ended ones, Ihey do givc Ihe i1dV,ll1l.lges 01 bOlh Iypes 01 sp;rnlle'
CombinMioIlSpolllll(!lS_IO, /1./2, 13. 14& 17mm Adjusl'lb1e sp,1I)n(!r . 9 inch Gcarbox/rellfaxle dfain/fdl(!r phlg key Spmk plug Sp.1f)fler (wllh fuuuef insert) Spilrk plu9 g,lp ,ld/uslmen( 1001 Set 01 h'elcf g<1uyvs Bf,lke ul(!cd l!IJ)plil spanller
SCfilwdflver -4 in long x '/ 4 ill dm (flil( bla(le) SCfewdriver -4 in /ollg x '/4 in {kl (cross bl,lde) CombinaliOIl pliers -6 inch H,lCks.1W (juniOf) Tvrc IWrl/I) TYfC preSSUfC gauge GrC,HC gun 011 C,?/! Fine elllufY c/ulh (I sheet) WIfC urush (slll.?!l) Funnel (IIIt'dium sile)
Repair nnd overhallllool kif Th(:~c 100iS ,1/(: vlllu;rlly eS~~"ll'o1llor anyOlle llnd(:rlirklno nlly 111,) rcp""s 10 " 111(110, vel"cln, <lnd all' ,1dd'l,on,11 10 Ihose U'v(,n III I M"'lJIlc'n.mcc' ;1/111 "lim" '1:1,.111 h~t. Included "1 IhlS 1r~1 I~ cOlllplclrellslv" sci 01 ~ockcIs. A llhouUir Ihese <rIC expensive 1111,'1 v I,e 10ulld uw;rluilille irS Ihey ale so v(:rS;II,le _ parllClilarly ,f V,l'" dllves ,l,e Included In Ill« S(;I, We fCconrl1lend lhe 'h m square· til Ivpe. a~ II1Is Cilil he used wllh mOSI propriel,"y 10,qu« wlr;I1 CIrt:$ If c;rnnOl ;rllord iI sockel SI:I, '!VCII hou(J1r1 piccellle;rl, Ihen IlIexp~;I'" lubular box spilnnels ;rrc iI usclul ,11Iern<lUve . The loois in Ihis IIsl Will Occ<lSlonallYllced 10 he supplelllcnl,,'1 100ls 1'0111 Ihc SIICC/.l/l,st.
Sudt'ls (UI box Sp,lllJlt"S) 10 cov~'r folflYC III f!fL'VIOUS IISI Rcvt'rSll!fe tilldlel d,ive (10f !Ise Will! sock(Jls) [xle,won plcce. 10 mch (fOf fiSC wilh sockelS) UIII\'(JrSilIIOJIII (10/ USC wllh sockuls) lOll/lie wrvm;h (fo, lise wilh sockeH) 'Molc' wl(JIfl; h 8 mch
f)""lw[JI "',mmcr Soll-I,lced I!;""tllcr. I,lasllc or rflUbl.'f Sc,cwrliivCt 6", /ooy x 5/
16 m ({,;, (1101/ "'ilde) SCf(.·IVdIlV"f -2 m lony X ~/f6 m squme (lIolI blilde) SClel",(/riv(J1 112 til lony x 1'4 /f/ di,) (ClOSS bl"de) Scrl.iovdllver . 3 II! fOllY x '/8 III dri, (c/uclflei,ll1s) Pliers deelllei,ll1S srdl.' CllllelS P/i(JIS IICI!llIe nosed PI,e,s c/lclip (mlefm" mllle,,-!,'''',)/} Cold eillse{· 1 '2 tlfel! SCllbe r
SCt.l/'(Jr
C(JII/le
l!Unch Pm {Jllneh Hacks,)w V"lv(J yrmr/mg 1001 SlCe/ mlelslfo1lghl·edge AI/ell A'eys Se/eclion of fries Wife brush (Io1fg(J) Axle, sl.1nds Jack (sirong Ifol/ey Of hyrlr,;ubc Iype)
Special IDOls
The lools III lh ls Irsl ;rre Ihose which arc no! used reuulo1r1y. 1\,. (:xpel1slvc 10 huy. 01 whIc h need 10 be uscd In accordililce wllh Ilor: manul<lClure,s' InslruCllons Unless rcf<ll'vely d,lt,cllll mech"nrc;rl )010 arc undertaken Irt:qllemly. II will nOlue cconomlC 10 buy many of I I lb· lools. Where Ihls is Ihe case. you could conside, clllbbll1g 10\) (:lh" wilh Iriends (or JOlillng 11 mOloriSIS' club) 10 mJke a 101111 purch<ls(!, 0 I)olfowlng Ihe 100 15 agalnsl a deposII Irom a 10Cili garage or 1001 hu. speciilhst
The 10liowing 1151 contaIns onlV Ihosc 100ls i1nd instrumenlS Ir(;(:I, Jvailable 10 the publrc, and nOI those spec,al 10015 p,oduced by II"
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Tools and workin g facilities
vehicle Ill,Ulur"Clu,C' spc'CIhcally fOf its deolc. network. You "",II hnd ()(;c(lsiOllal references 10 these manufac turcrs' s,) cciallools in the lCKt of this manu;!!. Generally, an allcrna live met hod of doing rhe lob w ithoul the IIchictc rn.1nufac h.Jlcrs· special 1001 is given . However, sometirnes. there is no allcm;l1ivc 10 using them. Where this is the case and the relcvanllOol CiinnOI be bought Of bo"owcd. you w,lI have 10 enlfuSI the woll" 10 11 franchised gaHige.
Vil/ve SfJllir[} com{Jfcssof (where ,1{JfI/ic.lb'e)
Pis/oil riny cOIIIII/esso! Ball/oim SCI/,llfllOI UniVCls.,ll1ulJlbCillill(J pI/litH Imp"el 5Cr(]W(lrtVl)f MicromClcf and/or vel Iller tpu{Jc
Diaf fllmye
5110/)OS(;01IlC lillliny ligh' Dwell ,1IIy/',' Int'ICI/I;,ciloll!c/cr Uni1lf!fsM e/c'·/IIC ,1/ III(II/i ·melef Cyli(l(f~'f CI/III/If<.'ssioo yml.lJc Lil/illy 1,1Clr.fL' TfOllcy;,1cJ< Ligl!l WI/II CII/t'llsion 1<.',1(/
Buying lools For prilctlcally all tools. a \OollaClOr IS the best source since he Will have a vCly COllll)lchenSlvc r,lnye COUlI);lfcd with the ,Wela!Jc U,l.ayc o. accessory shop. HavIIlU s;lld th"t. accessolY shops olten aile< eXCI:II..,nt quality tOOls at discount pllces. so It I>'"lys to shop aloulld. Remcmoo •. you dOIl ·t have t o buy the most e~I)()IISIVC ItelllS on the shell, but it is alwayS ildvisilhlc 10 steer cleil' 0 1 the vely cheap 1001s. The.e i1IC plenty 01 good 10015 alGund ilt .eilsonilhlc III ices. so .1sk the j>fop.ie\O. o. nl."lnilne. 01 thO shop 101 ildvico belo.e lllilklll\J tI Iltllchilse.
Care and f/1,1inrenc1flcc of lools Hilving I>urchilsed iI reilsonilble 100 1 kil. il IS nccess.1fy 10 k eel> Ihe lools in a clciln S()fViCCilblc condition. Allc. lise. illwilyS wipe all ,IllY dll" grc/IS(! illid Illcwl pilrticles \Ising ,1 clCiln. dlY cloth. belorc puu.ng Ihe lools aw"y. Ncvel le,wc thcm lYing alound alte. they have been used A sm,plc tool rtlck on .he l)ill;1\)e o. wo.kshop Willi. Imuelns such as screwdllve.s illHl pllels IS i1 uood idc,l. SlO lC ;111 "OIm,,1 w/{lllchcs ilnd soc kets II, i1 metal bo~. Any meilS\llu'\j 1115l1l1n1cnls. 1),lu\Jes.
metCIS. etc. IIH1S t ho c;rlehilly s taled whe.o they calmO! he d<l,,';1yed o. becolllc.usly.
Take a lillie calc whell 10015 ;lIC used. H"n1llle' hends in!Jvll<lhly becolllc lllillkc(1 and sCIewdllvc,S loso thc keen edgc 011 thcif bli1dc s
IrOIll tlillO 10 !IIIlC A "tllo tlillcly aHcrHlon with cnlclY cloth a. i1 role Will soon .eslole lIems "ko Ihls 10 ;1 good sClviceilble linish.
Workillg facililil.' s NO! 10 lie lo.gonen when dISCUSSII\\J lools. IS the wo.kshO$lltself. If ilnylhing mo.c Ihal' .outll10 !IIi1lnlCllancc os to be Cil.flt.'"il oul. somc 10'0ll of sUlwhle wo.king "'Cil becomes esscn"ill .
It IS al>PlcC'<l tcd thnt llI,lny iln owne. mcchtlnic is lo.ced by Cllcu'llstances 10 rcmovc illl Cllglnc o. siomlnr lIem. withoutlhe hcneflt 01 iI g,llilgC O. wo.kshol). Hilvlng done Ihis. <lny rep;li.s should alw"ys he done unde. the covc. of a '001. Whe.ever I>ossibie. <lny dlsmnmling should be dOlle on a clcan, 11,11 wo.kbench or tilblC i1t a Suitablc wo.king heoght An~ wo.kl)()nch nceds a vice: one with illilw opcning o f 4;n (100 mm)IS surtilble for mOSt jobs. As mentioned p.eviously, somc cleiln (fry StO'ilgC sp<lce .s also 'C(IUllod lor lools. ilS well as lor Iubllcall\, I . I . C canll1g 11~lds. lauch. up l)(lints and so 011. which 1I0coillc necessary Another ,'om which may bo .equirod. ilnd which hilS iI Illuch mo.c genc.al usaUo. 1$ all clcclric dflll with a chuck cilpacity of 111 leilSt 5 ;16 'n (8 111m). This, touCther wilh a good fango 01 twist dfins. 's vortuillly
Ossent,al fa. Iitting accossOI;es such i1S mirro.s alld wvorsing lighls. 1.,1SI. but not least, always keCI) a supply 01 old nowspapr:HS and CIOill1. 11Il1·f.ce .ags i1vailablo. ilnd tfy 10 keep any working MCil ilS clenn tiS POSstblc
JilW gal) (in)
0250 0.276 0 .3 13
0 .3 15
0 .31\4 0.3 54
0 .315
0.391
0.'133
0
.'138 o 4il5 04?:? o !l00 0512 0525 0551 0563 0591 0600 06'5 0630 0669 068. 0709 0 :110
0 .7"8 0'/50 0 .813 0820 0 .866 0875 0920
0938
09il!) 1000 1.010 102 4 1063 I 100 I 125 I 181 1.200 1.250 1 260 1.300
1 .313
1 .390
1.417 1 1138 1480 1500 \.575 1614 1625 1 .610 1.688 1 811 1.813 1 .860 1 875 1969 2000 2050 2.165
2 .362
Spilnner si~e
11~ in AF 7 mnl 5 1 16 in AF 8 111m !lIn 111 AF. 1/8 III Whnwo.lh 9mm 3/1;1 ill AF 1 0 I1ml 11111111 '/ Hi III AF 3/Hi in WhilwOlth: I .~ 111 BSF 12 mill 'n 111 AF 13 nll11 1/
4 in WhllwOllh, $/16 In BSF 14 mm 9116 in AF 15mm 5/
16 in Whitwo.th. J 8 in BSF $/s in AF 16 mm
17 nlln I ' /Hi In AF 1 8 Illlll 31 8 III Whitwonh; 1i16 on BSF 19 mn, 3 /
4 in AF 13/16 ill AF 7/1 6 ;n Whilwollh. 1
/ 2 in BSF 22 Illm ·"8 in AF 1/1. in Whi,wonh; 9" 6 in nSF 15/
16 in AF 2
4 nlln 1 in AF 9/16 ill Whitworth. 5/
8 OIl BSF
26 """ 11/16 OIl AF: 27 mm 5:
6 i,l Whitwollh. 1 1/ 16 in BSF II/a in AF 30 111111 111 161n WI"lwO'lh. 3/_ 111 I3SF 1 1
/4 III AF 32 Illlll 3 ; 4 III Wh,twonh. 1 a In I3SF 15/16 OIl AF 13/16 ;n WhltWorlh. 1~/16 In BSF 361ll1ll 1
'/16 in AF 1/ 8 in Whitwolth; I in BSF 11/7inAF 40 mm. 15
/16 in Whltwo.,h 41 nun 15/a in AF 1 III WhilwOflh. 11. 8 i n BSF
111/16 in AF 46 111m 113/16 III AF II/a In Whi,woflh. III~ \1 nSF
1 1
/8 in AF 50 nun 2 irl AF 1'/~ in Wh,lworth; 1 3
/8 in BSF 55 mill 60 Illm
11
procarmanuals.com
Page 13 of 205
" .
:ansa
Safety first!
Profession;!1 010101 mechanICS Me , .. ,oned in sare working I)'ocedures. H owever cmhusillshC you Olily be "houl gcuin\j on with lhe job In h'lnd. (10 lake the t ime to cnsule thai yOl" safely IS not pul11t ,isk . A rnomcnt"s lac k of attentIon car, resul t on an i1ccidcn!. as can fnollJJC 10 obSOlvQ COlla;n ClemCIlI,l,y precautIons. There will alwilys be new ways 01 h;IVUlU ac c.ttenls. ;111(1 'he following points (10 not p.eICn d 10 he! n cOlllplchcns,vc liS! Or <111 d,lIlge.s; Ihey ,lI C inlt'!I1dcd rathor to milkc you ilW;UC or the ',sks nnd 10 encourage II sn le ly -conSClOus ilpplOilch ,<> ,,11 wall" yOIl C;l"y OUI all YOUI veluelc.
Esscllli,1/ DOs nnd DON'Ts DON'T .cly on a SU1U1c Jack whtn wOlk'''11 undc'tlCil!h the vchlcle Alwilys usc rch<lulc add,lton,1' m ea ns of SUP11Ott. slu:h ;;IS axle SI;Jnds, securely placed undCl ,1 p.lrl 0 1 Ihe yehi cle Ih"l you k n ow w rll nO I wye W<ly, DON'T DI1Crllp IIO loosen or IrOll1cn IU\Jh'lOr(J"e milS (e ~ wheel hul. nulS) whrlc Ihc IIchr cle .s on D IDd. ,I m .. ly he pullcd 011 DON'T sW'llhe cnUlI1e w,lhoUI I •• ~I asc r"w.n.nu Ihallhc 1I.1'ISllU5S'0" ,s on neulral (or '!'D,k' whe'e DPI)loc,ll,llI) <lrld Ihc p;r,ku'!J h',lkc ;rpphr,d DON 'T Suddenly rerllOIlC the folic. c.'p frorn .1 hOI t:tluhrl\J system COlier il wllh D clOIh <lnd .clcase Ihe p",:,~",f] !1.»dually ',,:.1. or you may
!Jct
scDlde d by CSC"ll'''U cool»111 DON'T allcmpllO d •• 1Ul 0,1 unt,1 you ;IrC SI"C 'I ha s t;uolcd suUrC'crr lly 10 allo,d scalding you. DON'T yrasp any Il"l! 01 Ihc cngll1c , e~h,l\lSI or "'I; ,lyt 'c r:onll'''IC. w.thoul 11151 aSCe!l""II"~ IhD I II IS su fl,c'ently co1J1 10 avoul hUlllln!1 you. DON'T ,lllow brilkc UUld or anllfr eeze 10 conwct vc hlt.le P<lllltwo.k. DON'T syphon 10K'C Ioqu,d s such <IS h, el. hr;lke flui(1 or a"t,hee~e lJy moulh, o r allow Ihem 10 'emall' on your ski n. DON'T inhalc dusl II m.1y he "'IIIIIOUS 10 hCJhh (s.~ A sIJcs lUs bclow). DON'T nllow any s pd t Oil 01 \l'liasc 10 leillaln IJn Ihf]II"OI wilH! ,t up sl/aiyht awDy, bclo.c somcone SIoI'S on .1 DON'T usc 11I·llll",,, s",lnnms 0101 1"" Il)uh wh .. ;h may ~lrp arul ca,,~c I"Ju,y. DON'T HlIellllltlO hit a heavy COIll!lorwnt whlt:h m ay In: J",yoml your ~ap"LrllrlY yet aSSistance DON'T Ilish 10 I,msh D Joh. 01 tiokc unyellloL·d sho.t cu' s DON'T allow ch Ildren 0' alll",~ .ls III 0' ~"rJII"d;", 111I1'1I.",d"d vch,clc DO wCJr eye protecllon whcn usmy powe, 10015 such ;r~ dll". s~l1del, Il1:n<:h w'nde' etc. and wh"n wOl kln\) under Ihe Yel"c lc. DO use a bil",er c.eam on yuu. h al\(ls pliO. to undcrtakrnu duty Johs II will p.otcC t you. sku , from ",IeChon as w,,11 as rnakrnu Ihe dUI cas,c ' to .emoyc afte.wa.ds. h". make sure your hallds <l",,1'1 Ictt sh pper y.
NOIC 110m lon!j"tell11 coni ac t wllh use d ell!l'lle oil r.DIl be or h ealth hala.d. DO keep loose clothlny (culls. hC elc) and lony IIDn w!:11 aliI 0 1 th e way 01 mOllllly l11echamcal pa'is DO .emOllc linus. wnstwmch e tc. helorc WOlk"I!J Oil Ihe veh,cle
espcci<llly the elc cillcal sys!(![) DO ensure thm any hltin~ tackl!! us!:d has a sale wOlklng load ';Itln~ admJualO tor Ihe ,o b DO kee p yoU! wo.k a.ca I'dy rt ,s only 100 eas y 10 fall oye r .. "tlclcs teft tYll1g around. 00 get sOl11eone to c he ck p erro dlcally Ih"t <III IS well. when wOlking illone on the ve hIcle. DO carry out wor k in a I()(Jica l sequence alld check that eve.ythlllg is correc.ly ass ernhled ilnd t'ghlen ed aftcrw.l.ds. DO .emembe. that you. yehlcle's salely <lHects tl1ll1 of yourself Dnd olhers II in douhl on any poinl. uct speci"hst advice IF, il1 s p ile of follow ing 'hese p.ecaullons. yoo a,c unlo.lunOlW cnough to In)ure you.self. sec k medical illlention as soon OIS pOSSible
Asbestos Cc.1;Jin trICI.on. In sutatrn u. scalrny. ;Intl Olher l)roduCls SUCh as b.<lkc hninys. blake bands. clulch tmongs, tmquc conyc.le.S. ~askels, elc -contam asl)C Stos EJllIem e C,lle mllSI be wJ-.en 10 ,l\foid mhll/{llioll QI dll)'rlwlJJ such l)lorltlL"r~' since II IS IUI"~f(/OIlS to Ilehfl/l If on doubl. nssumc thai they (/0 coniJlI1 ashe~los
Fire Rcmembe. al all tunes that pelrol (uasolone) IS hiyhly flaIl1ln:r. N eller smokc. or h.we .1ny kind 01 n"ked tlamo ,1round, wher) wo,! on Ihe vehicle But thc fis k docs nOI end thc.e -a spa.k cauS!:d 10 elccu lca l shOll ·ClrCIIII. by IwO nletD I sUIfaccs contaclinu each oth .... coue lcss IISC of lools. a. eyen by 51,'Ik eleclrrcity bUilt up III you, I·· unde. Cellnll1 condilions, carr Iynite petlol vapour. wh,ch III or t.orrf "
sp<lce IS highly cJlplos,ve Always disconneCt the hallery eD.th l!J,ound) temu,,;" 1>,·1 wOlk"l!J 011 Dfly pall 01 Ihe fuel o. elcc'"cal syst em . .11111 nl:vn, splllrnll Iuol o n 10 a hot engll1e 01 exhaust It 's ICf.om",,,nd,,(i Ih. ll .1 Ille cKtll1{1Ulshor o f a (ype su,I;rlJh: 1o, nll< 1 "leclIICnllues IS k"pt h<lndy ,,1 IllI! !)<I.a(Je n. wOlkplace;o1 <In I,,,
N fN(;' (.y 10 e~lln\Ju.:.h .1 luel or clecl.ic<l1 lue Wllh wal!: .
Fllmes CertJ IIlIUlI1!: S are 11IIlhly 10X 'C arrt! can {IU,ckly cause Ullcnnsc",
IIIlSS ;1IId evcn de,llh ,llIlh;"ed 10 any exlent Pel.ol (!I<lsolonf:) y;'I ' cnmns mlO Ih, s cate~o.y .• 1 S do Ihe vapou.s I, o m Cf],1<1111 SOlv",,,,., '.' a s Ilichiolocthylcne Any dr<lll1l11\J Of pOlHlI11l of suc h yul.llIl" 1\" ~ltould be dOll" III .1 well IIcntilaled ;IteD When IIs'ny clcanliln flUids .lnd solvents. '''<ld lit/! III~.I"" tl' c;"l,dully NOlVIl ' usc ""ncII,lls hOI1' u,un'llkcd COlllallll:lS Ih"y" "'V" ufl po'sonuus V;rI)(lUI S
Nev,,1 'lin lloe "III)ln" uf ~ motor vehicle 111 nn Cllclos(,( 1 ~pace '.1 ns il U.1r,)\Je Exhau st h,m(;s con1<111l Ci'lIUOrl mOlloxlde wh"'h ext.emcly poisonous. , I you Itemf 10 run Ihe engine. always do so I'" o l)en <llf 01 011 ICOlsl h<lve Ihe ,em of (he vehicle outside 'hc w o'kpl., 1/ you <lre lortullale nnough 10 have the usc of OIn inspCCI'OIi
IH.:ver d.ain o r pour pet.ol, nnd neyer .un Ihe engine. wh,le Ihe ve lll IS S1<lndin~ ove. II; (he h,mes, beinU hca yier than ail. w<1I concent/;II ' the 1)01 wi.h I)(lSsl hly lelhal ,esults .
The I1M/ery Never cnllse a spalk, o. Dllow n naked !rUIH. noa. 11m voll" I
h;1\1I:'y II WIn no.",,,lly 1m !JIving 011.1 co.tam al11o"nl of lIyelll'!I'""'<
w h,,; h IS hl\lhly cx, )loSIY c. Alw;.ys dlscon,,!:!;' Ihe hatlc.y e.1.lh (wound) 11:,""11.,1 1,,·1. wo,k,n\) or' Iloe: fuel 01 CI'lctrl~'11 ~ystll"'~ II possl hl() . looson the frller pl"ys or COYer when d,;oQIIl1(1 I
h ntte.y trorn an extern,,1 sou/cc Do n ot chJ'Ue .11 an ()xCCS~'y" .,,1, the Ihllle.y 111,1y hursl Take cal(! when 10PPInU up nnll when cally,nu the h.ltIC'y lh'I.' I:lcctlolvtc. eve n when drlu led . <s Ycry COrrOSIVe ;)n( 1 ~houhl ""I .lllowed 10 conwct Iho Cyes o. ~ .. '" If you eye. need to p'Cj).1H~ eltl<:l.olyle you'Sctl , alwOly S ,1{ld the .. ' slowly 10 Iho) wOlle •. ,lnll neyer the o lher way round Protec • .1(1""
S plilshes hy wea""y ruhbcr uloves Dnd go~gles Whe" JU"'I) stnlt"'u 01 ca r uSlI1g a booster uatw.y. to. negDllv c l'" (wound) vehicles. connecl Ihe )U"'I) leads in t he follow,ng S(){ll"'''' F"st connec t one ,orn ,) lead belween Ihe posllive ( , ) le"',,,,als 01 1 Iwo hallelieS Th,,11 conneC I Ihe Olhc. jump lend lust 10 Ihe neIFII ' ( ) lelmll1 0l 01 Ihe booster hOllery. ilnd then to 0 good eDrth , (groun(l) pOonl on the lIehiclc t o be starled. 1llleas t 18 in ( " 5 erll) f" Ihe hatte.y If I)(lSs.b lc EnSUIe thot h onds and Jomp leads ".e CI C.1, any mOllln!) P<l.IS. <Inc! Ihal (he IwO vehlclcS do not touch . Dl scon". the ICild s 111 lhe .everse order.
MaillS elec tricity When lOSing an elec'ric powcr 1001, in SpeClio n htthl e.c. wh .. wo.ks fro m thc maIns. always ensure Ihm Ihe apphonce is corr(:( ' connected to It s plug nn d th~l. where necessa.y, il is properly eilrlh. (grounded) Do nOI use such Of}pliilnCes in damp condilions ;" agilll1, bewa.e of ereahnu a spa.k or applyillU excessive heal In I'
VIClnlly o f fuel or fuel vnpour
Ignition fiT voltage A seve.e elect"c shock can result from touching certarn parts 01 tl
Iuni lion sySlem. such a s Ihe HT leads, when Ihe eng,n e 's runlli/Hl being cranked. p<I.llcularly If componcniS are dnmp o. the insul<lllOll
d efective . Where an elect.onic 'ynltion syst em .s filled . the HT volt .. , is much hluh(:r and could plove lawl.
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procarmanuals.com
Page 14 of 205
Routine maintenance
Maintenance is essential tOI C"~l"'Il\J sal"I\,. <lnd de~",jt,l" lor \I1 purpoSe o f gening the best inleflll~ of peduPlllilllCr. nnd economy 110m yOlir car . Over the yeilrs the need for pCflodlC lubnc;lIlon o,II,,!!. gle~slOg ;md so on -hilS been drilSl,cnlly I(,duced. Jf not totally ellmmfllcd. This hJS un/ortllll,lIely Illnded to 11);1(1 sonle ()wn~,<; Illilunk \h<1 because no such action IS tCqLllrox l, f.ompol1,:nb I1,\h ,,, n o 1111\0'" e~ist. or wdllast forever. This is J ~;''''OUS (h:hJS IUII If fOllows [ I""do ,t! thm the t,nges t in;I;;;!1 elcmelll 01 1lI;lIntP.l1olll!;fl IS VI$uil l "X;lIllll1dll"ll and a general sense of awmcness Tills Ill;]\, IC;l(llu [UP,l"S Or ",,,,,wals.
Inll shou!!1 1,,:11' 10.'1'0" I !(l,l(bulc hre,lldowlls. Other neglect resul1s In ullrehillllhly, "H:I(~as(;d ,"nnlll!) COSI~, morC) rnpld weM (lnd depreci. (Ilion of Ihe ".,judI'! III !I':II<: ral
The 1"II<)wII'~1 Sr:r",,:,~ schedules ,"lJ ol I rS I of the maintenance req<IIIf"l\,~'llS 0111<1 Ih" 1I1I':lVol ls <ll wlll(.h Ihey should be cDlfied out. Wiler" appl,r."I, I" lil,:s" I"oce([urcs 01", r.ove ,ed In 9,e.Jle, deta,l IhrOll!)hOlll 111I~ 011,11111"1,1(',,, Ihe hCOUIIH"U of .lach C hnplCr or ChapWr ([IV'S'OII
' .
.
,
. . c;~
~--------------------'--~~~~'~ <i.; ...... \~) ---',..." _. ____ m .' &§Sf" ;)
View of engine compartment (2.B Injec tion)
I Br,lke St'fVO uni/ 12 A" mIN duct 21 f/,ld'o,IOI l"lm c:,/, 31 Coohng sys/em pressure 2 Slarl v<lIve I.? /!lflrllOll carl 22 R<!ill,'/01 C,l!) and CXP,lllsion l<lnk 3 Dislribulor cap 14 Powel s/Ccrmg lIu/(/ 23 AII<1II1<!/()1 32 81,lke master cylinder .] Windscrccn WII)Cr <111/1 wservOll 24 /-/e'l(/lig/'1 aCet'H ':IIV('I 33 F'OIlI suspension top 5 Headlamp rc/, lY 15 Warm I'I! ICYIII,1Im 25 BiJlIl :'y ",0(1l1liIl9 6 Windscrccn washcr 16 PVWL'r s/eeli"y Im"'I' 26 rOj! how 34 nr,lke 1I(1ld ICS(Hvo ir rcservoir 17 DI~/I ,/)ulu, f 1111 xl,,, t' Cl!IJlr "I 27 Dllv"'g "!J/II,d:ry.'llI~e ,,111/ 35 n,..,kc IIUld low Icvel 7 Igllilion mllpl,'ic, 1II0du/,: (11111 28 "wlfllollllle Sl1 lid, cll.:cAiny mClllbr,lllC 8 Fuelliller 18 1111 dUollle, body 29 COUldll 1 It'IIIf!"'''II/IU scndt'l 36 V,lC!l1II1! hose 9 Enginc oil !rllvr C,lf! 19 /JOlllle! sl,"ly IIrIIl 37 Fuscbox 10 Tlf(ollle lrousiJl!) 20 PIIWI]{ s/eC11I!9 11IIlIlf) 30 AII.rt,oIlY .-IIt "~'V't'" II A i, chambcr dflvt:/!r.:/(
procarmanuals.com
Page 17 of 205
" ,
'6 Routine maintenance
)
Every 250 miles (400 lUll) or weekly -whichever comes first
Check the engine 011 level and lOp up " OCCCSSJry (Chapler 1) Check and adlus t lhe IYIC pressures (Chilplcr 10) Clean the windscreen and windows C lean the hcadlamps
Every 6000 miles (10000 km) o r six Illonlhs - whichever comes fir s t
£II[1ille (Clwpter 1) Change engllle 011 and IIher
Cleiln oil flilm c"p Chcck 10 1 ,IllY fluid leaka!)e ,n enUme CO'llp:lnUlCIl1
Cooling syslem (Clwptet 2) Check cool:'lnt level
Fuel syslem (Clmpler 3) Check idh"U mi~lUle (cmiJUiello1 IllUdels onlv) al I"SI se.v,ce ollIe, overhaul C heck idllllg sj)ee d
Ignition sys/Cm (C/I,Wler 4) Clean ,1nd re!)"p Sl)".k plu!)s (.:on!nC ' breilkCl Illudels olllv) Cle an and check d'Shibu\o. C"I). '010'. HT lealls mId co.1 (COllWct
bleaker modcls only) Check elwell angle (cOntact b.e"ke. mo<lel s only) Check i900\OOll hlllillg (COnt:'lC1 break er models only)
Cllltch (e/Mllter 5) Check adjuSlmenl
Bri/king sys/Cm (Ch,1pter 9) Check selva
Che ck hydraulic flu id h,vel
Ch(: ck p"ds :'Illd sho(:s lor wear Check h.ake hllcs and hoses
Suspension .wel stvi'ring (Chi/pICr 10) Check tyres 10' w ear and dam:lge Check steering COmp{lIlCnlS l o r w e:l l "lid d.1nlilue
Bodywork. .111d fittings (Clwptef 11) C lu .. >ek se"t belts fa. we .... damage :lnd secwity
Elvc(ric.11 systcm (Ch,7jJ(ef 12 ) Check Ope.iltoon 01 "Uhts Check wilsher flUId levels Check b.1ltery eleclrolvle lev el
Every 12000 miles (20000 kill) or 12 mOll1hs - whichever comes first
III .1(/(lIlioll 10 Ihe 6000 m/le sciler/Ille
Engine (Ch.1f)ter 1) Check and adlUSI valve clearanc es
r"' .......... ~.~-.... ._ •• -.... __ .... . 3lii1&l •
Cooling system (Chapter 2) Check condition "net tension of 1111011)<1101 dflvehelt
Fllel sys tem (Chapter 3) Tighlcn inlel IIHlnl lold boits/nuts Check vacuum hoses Check e~hiluSI syst em Check ll1r ctonne. temperature cOllllol (,I applicable) Renew fuclllllC ' (fuel injec tion models only)
Ignilion system (Chapler 4) lubricate th e dis'flbulOf (conUlel br eake r models only) Renew the coninCt hu,akcr points (II nppllcJblc) Renew the spMk plugs
Transmission (Chapter 6) Check ool/th"d level Lulmc;ue automatIC 1.,'Insmlss,on IInk:'lue
Rcar axle (C/MplCt 8) Check 011 level
Bli/king system (Chaplet 9) Check v,lcuun' hose
llliJllc:'l1C Ihe handhlake Imk,loe
Suspensioll {//j(J swelill!J (C".1plt~( 10) Check condItIon and hlllSlon o f POWI.II ~I!'tllllli dllvthtl1 (II .1l1pllcal,
Check MlspenSlon 101 we;" ;111(1 d;1Il1.1!)e
Bodywork ,1I)d fillings (Clwpler 11) Check opera lion of all locks Check secu.ity 01 dOOf check sl.aps
LlIl)fIcalC locks. door c heck S\','P5 :'Ind fuel fdler cap flap
Check underbody pr olCctive coalm!)
Electrical system (Chapter 12) Check Opcra1l0n of all eleC111!:al IIcm5
Evcry 2<1 000 llIiles (40000 kill) or 2 yc;u s -\Nhichever comes firsl
III ,1(/111/'011 10 the 12000 111"'1 $d'~'f/u/e
[nyino (CIWpICf 1) f!ell'!W crankC:l $e e""5510l1 v;llve
Cooling syslofll (Clwptor 2) Renew COO!:1II1
Fllel SYS(CIII (Ch, '/pliJr 3) Renew"" II Ih!r elemenl
TrallsmissiOIl (ClwjJWr 6) AdjUSI aulom;1\IC trall5nll5SIOll h,ake b;'IIld
Every 36000 miles (60000 kill) o r 3 yenrs - whichever comes first
III .1(/{/I('01l 10 Illc JJIl'VlOUS schc(/ulcs (",lIc" JJJIJ"ci,bfc)
Brakillg system (Clwpter 9) Renew hyd,auhc flUId
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Page 19 of 205
' ..
Conversion factors
Length (dis(,1IIce) Inches (Ill) X 254 MIII,mClr(:~ (nun) X o 03!l4 FeCI (h) X 0305 MCI,(l~ (111) X 328 Miles X 1 GO~ Kilolllc(.r,s (kill) X 0621
VOlllflll! (C.~/J.1Cily) Culm: lIu:hcs (eu 111. Ill') X 1 G 367 C,d"c ("nl,met",,; ("c. CII1') X 00131 IIl1PC",llllill1s (hill> pL) X o G68 L'II,-s (I) X 17G ''''(JeIl,11 CltJ,"IS (11111) ILl) X 137 LI''''~; II) X 088 ''''11C'',11 (1,,;'115 (11111l '(1) X 1 lOI uS 'III;"'" (US 'II) X 083) us qlln'ls (US (11) X on·IG L,I11!S II) X 1 057 l"'pe",,1 (pllons (Imp (I~I) X <1 !;4l,) L,I>, -5 (I) X 0" l"'p,,";11 !Iillions (Imp 11011) X 1 ]01 US !j"II"n~ (llS !i.II) X 0833 tiS Bailon,; (US Hal) X 3785 L,',.·s (I) X 026·1
MilH (wl!ighf) Q"nr.cs (OlJ X 7835 G"",,~ WI X 0035 Pnumls (110) X 045·1 K"f"J,."ll~ t~B) X 2205
F()ICI! O"'u: ,,,; I", cn (OIl, (/) X n i'1t!
N''WI'''IS (N) X 36 I'o",ul'; Imr.e (lhl. Ih) X 1 1\.18 N"Wl""~ IN) X On~j
N"wt""s IN) X 0' K'h".: ... m~ I.",:" \~.!11. ~ 'I) X !'lSI
PIt.'SSIIfl- ' l'oun,'~·lnrce 1,1,;1 SIIUil!!! I"dl X 0070 K,lo!!,i"" S 10" ;" i'''' SqUi'''' X 1'1223 (p:.': IIM,n', lbjln') ,:1 ,111'''''''1''' (~!II/c:m'. k!l /cm') I'mll1(ls·lolce IICI lOq";"!! ,"ch X 00G8 Au"" .. phc"" (,,,"'1 X 1.1696 (ps'. 1101/'11'. Ib,"II')
1'0Ilnds ·lo,ce pc. 5'11"',e ",,:h X o OG9 B;,,~ X 1.15
(1'5'. ItJljm'. Ih/m') Pounds· fence I)()' $(I"".e ,,,r:h X G 8% K'I()p"scal~ (!d' .. j X 011\5 (pS I, Ihl /m'. IIl/m'l K"np.1 sr.als (kl'.1) X 00' K""!!'i""'; '''1(;'' I"" Sqll,11C X
'" •. unl,,,,,,I'e (~~,Il.:m:, k!I ,·';"'· M,n,Io,H (mha. ) X 100 1';,,,,',,ls (1',1) X 00' M,I\ot.,u (mh",) X 0011\5 PI,unrb "lOti! 1":' "'III,,,e '''.-\, X 68 !J<l7 (p~,. lI,t ,,,'. 110/"':) M,II,I"" (ml,;,,) X o ./!, M,lh'''I'I'uS "I ,,,(!,, :u'y ("",,'IU) X 1 333 M,llol, ;" (mh;" ) X 040 tou: lI"s "I wah" ('''11,0) X 0711 M,n"""huS 01 '"() 'CI"y (n'nlIi!l) X " .. Im:II,,.,, "I W,lh:r (,,,H,O) X 053~ I"d",:; 01 W,"", (mll,O) X " .. Pounds In',:c III!' t>llu",e oneil X 0036 (ps'. II,! ",: IIl/,n')
rorqllc (momCllf ollorce) Po"",ls·lo<cn mclles X 1 152 K"o!l"H"S loO\:c co:IIIII"" lIe X 0868 (Ihl "I. Ih on) (~!JI (:111. t.!! em)
I'nunrls·t o,ce ,nc he,; X 0113 NI'Wh'" ""'I,,,,; (Non) X 8 85 (Ihl 'II. III ",) 1'0"ncl s·IOICe Inches X 0083 Poumb lo'cu ICCI (Ihl h. lb it) X 12
(Ih l '". IIJ 'n) l'olO,,,ls·Io,c\! 11,;,,1 (Ihl h. II! h) X 0138 KoIulI';,,"s·tn,cc "",I"IS X 7233 (kill m. ~\, 111) Pounds·la,ce l e cl (Ih l h. Ih h) X 1356 Nuwlon mel,cs (Nm) X 0738 Newton met.es (Nm) X 0102 K,IO<J.;lnls· lo.ee met.es X 9804 (kgl m. \..(1 m)
Power Uo,se,}Qw,," (hll) X 745.7 W;IIIS (W) X 00013
VI!/ociry (speed) M, les pe. hou. (1IlIIes /h •. mph) X 1 .609 . Kilometres pc. 110ur (klll/hr. kOhl X 0621
Flwl cOllsumprioll' M,les poll gil1l0l1, Impcllill (mpg) X 0351 K,loon"ucs pc. 10(11) (kill /I) X 2825 M,les pCI 1).111011. US (mpu) X 01\25 K,lolllct«)s II .... lot" .. (kon/I) X 2352
r CII'pcri/fmc
Oey,ec. s F;lhrenhc' l - C ~ 1 8) . 32
.// IS cummon pr;/Clit'l! I U CQIlVl!r l !tOIll miles per y,ll/,J/! (I1IPY) IU IIlres/IOO ~"omelrf!S (1IIOOk l1l). wlletl! "'PY ({"'pl!t/iII) x II 100 Am ... 282 iJnd III/IY (US) ~ If 100 km '" 235
(nchl,~ ('n) FCCI (it) MIl(:s
Cu b,c "H.I",~ (O:u Ill, 'n') 11111)1"",1 poulS (Imp 1,1)
"nile"", '1";,,1 5 (11llp '11) Imp<,,,,11 'l"o1"s (Imp '11) US quaots (US 'II) hUIl""al 1I.1110<1S (lu,p (1.01) IlllpcII.11 U.,lIous Pl11p 11,,1) US ~F'IIOfb (US !1.1IJ
QUilt:",; (U/) f'()"ml~ (Ih)
OlJll<:"S I''',.e (nd. ", ) l'Oun,b lo,r." (H,I, Ih )
Nl!wlon s (N)
Pounds·lo,c!! 1)1;' Stl""'" Inei, (ps'. II,I/m'. Ih /m ")
POllnds· lo,ce pc. 5(1",1.e II".:h
(pS'. Ihl/m'. Ih/'''') I'ounds·lo,cn I)er sq"",,, ",,:1 (pSI. tlli /m'. Ih/m') Pounds·I')lCll pel SlI"ille IIKII
(ps,. Ihl/Ill'. Ill.',,,') K"llpa~cal~ (~I',o)
M.n,t"" (,,,,,;,,)
M,ltoh;" (mh",)
M ,n,I"" (mha,) M ,n, t .... '. (mlom) M,nunet.es ot ",c.cuoy (nHuH!]) Inches 01 W"h" (II1H,O)
Pounds·IOlce 'ncheS (Ih l Ill. III '") Pounds·loocl,; 'ncllUS
(Ib l on. III 'n) I'ounds-Io,ce IIlches
(Ib l in. Ih ,n) POunds ·fo.ce l<,let (Ibl II. III h )
"
ounds·lorce Ic.el (Ibl h. Ib h)
NeWlon met.es (Nm)
. 1I0.sel }Qwer (hll)
. M,les pc. hour (rniles/hr: mph)
M, les pe. 1),1110n, Impc.roal (mpg)
M"es pc. »;IItOlt US (mpg)
(F·32jx056
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